Introduction to Mechanical Engineering Module 2: Engine, Future Mobility

1. What is an Engine?
An engine is a machine that converts energy into mechanical work. In most common engines
(like in cars), chemical energy from fuel is converted into mechanical energy to move vehicles or
drive machinery.

2. Types of Engines
Engines can be classified based on energy source and working principle:

A. Internal Combustion Engine (ICE)

 Working principle: Fuel burns inside the engine cylinder, producing high-pressure gases
that push pistons.

 Types:

1. Petrol Engine (Gasoline engine)

 Spark ignition (uses spark plugs)

 Lighter fuels, higher RPM

 Example: Cars, motorcycles

2. Diesel Engine
 Compression ignition (no spark plug; fuel ignites due to high temperature)

 More torque, fuel-efficient

 Example: Trucks, buses, ships

 Cycle types:
o 2-stroke – completes a power cycle in 2 strokes of the piston

o 4-stroke – completes a power cycle in 4 strokes of the piston

B. External Combustion Engine

 Working principle: Fuel burns outside the engine cylinder.
 Example: Steam engine, Stirling engine.

C. Electric Engine
 Converts electrical energy into mechanical energy (used in electric vehicles).

3. Main Components of an IC Engine

1. Cylinder – Where combustion occurs.

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2. Piston – Moves up and down due to combustion.

3. Connecting Rod – Connects piston to crankshaft.

4. Crankshaft – Converts reciprocating motion into rotary motion.

5. Valves – Control intake of fuel/air and exhaust gases.

6. Spark Plug / Injector – Initiates combustion (spark for petrol, injection for diesel).

7. Flywheel – Maintains engine momentum.

4. How a 4-Stroke Engine Works

1. Intake stroke – Air-fuel mixture enters cylinder.
2. Compression stroke – Piston compresses the mixture.

3. Power stroke – Spark ignites fuel; explosion pushes piston.

4. Exhaust stroke – Piston pushes exhaust gases out.

5. Applications
 Vehicles (cars, trucks, motorcycles)

 Power generators

 Marine and aviation engines

 Industrial machines

Petrol Engine (Spark Ignition Engine)

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1. Definition
A petrol engine, also known as a spark-ignition engine, is an internal combustion engine that
runs on petrol (gasoline) and ignites the fuel-air mixture using a spark from a spark plug. It converts
chemical energy of fuel into mechanical energy to drive vehicles or machinery.

2. Working Principle
The petrol engine works on the Otto cycle and follows these main steps (for a 4-stroke engine):

1. Intake Stroke
o Piston moves down, drawing in a mixture of petrol vapor and air from the
carburetor or fuel injector.

2. Compression Stroke
o Piston moves up, compressing the air-fuel mixture to increase pressure and
temperature.

3. Power (Combustion) Stroke

o Spark plug ignites the compressed mixture, causing rapid combustion.

o The expanding gases push the piston down, producing mechanical work.

4. Exhaust Stroke
o Piston moves up again, expelling burnt gases through the exhaust valve.

3. Main Components
 Cylinder & Piston – Where combustion occurs.

 Spark Plug – Provides ignition for fuel.

 Crankshaft – Converts piston movement to rotational motion.

 Camshaft & Valves – Control intake and exhaust of gases.

 Carburetor / Fuel Injector – Mixes air and fuel in proper ratio.

 Cooling System – Prevents overheating (air-cooled or water-cooled).

4. Types
 2-Stroke Petrol Engine – Completes a power cycle in 2 strokes; lighter and used in
motorcycles, scooters.
 4-Stroke Petrol Engine – Completes a power cycle in 4 strokes; more efficient and used
in cars.

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5. Advantages
 High speed and smooth operation.

 Less vibration compared to diesel engines.

 Lightweight and compact.

 Quieter operation.

6. Limitations
 Lower thermal efficiency than diesel engines.

 Higher fuel consumption.

 Less torque at low speeds.

 Petrol is more flammable than diesel, posing safety concerns.

7. Applications
 Automobiles (cars, motorcycles, scooters)

 Small machinery (generators, pumps)

 Light aircraft engines

Diesel Engine (Compression Ignition Engine)

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1. Definition
A diesel engine is an internal combustion engine that operates on the diesel cycle. It ignites fuel
by compression rather than a spark, which is why it is also called a compression ignition (CI)
engine. Diesel engines are widely used in heavy vehicles, ships, power plants, and industrial
machinery due to their high efficiency and durability.

2. Working Principle
The diesel engine works on the principle of compression ignition, which means:

1. Air Intake Stroke: Air is drawn into the cylinder.

2. Compression Stroke: Air is compressed, raising its temperature significantly (up to ~500–
700°C).

3. Power Stroke: Fuel is injected into the hot compressed air. The fuel ignites
spontaneously, producing high pressure that pushes the piston down.

4. Exhaust Stroke: Burnt gases are expelled from the cylinder.

This cycle can be 4-stroke or 2-stroke.

3. Diesel Cycle vs. Petrol Cycle

Feature Diesel Engine Petrol Engine

Ignition Compression ignition Spark ignition

Compression Ratio High (14–22) Low (8–12)

Fuel Efficiency High Moderate

Fuel Diesel Petrol

Torque High at low speed Lower at low speed

Applications Trucks, buses, ships Cars, motorcycles

4. Components
A typical diesel engine has:

 Cylinder block and head – house the combustion chamber.

 Piston – moves inside the cylinder.

 Crankshaft – converts reciprocating motion to rotary motion.

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 Fuel injection system – injects diesel at high pressure.

 Valves – intake and exhaust control airflow.

 Cooling system – prevents overheating.

 Lubrication system – reduces friction.

5. Advantages
 Higher fuel efficiency

 More torque at low speeds

 Long engine life

 Safer fuel (less flammable than petrol)

6. Disadvantages
 Higher initial cost

 Noisier operation

 Heavier engine

 More expensive maintenance in some cases

7. Applications
 Trucks, buses, and lorries

 Ships and locomotives

 Generators and industrial machinery

 Agricultural equipment

4 Stroke Petrol Engine

Working of a 4-Stroke Petrol Engine
A 4-stroke petrol engine completes one power cycle in four strokes of the piston, which
corresponds to two rotations of the crankshaft. The four strokes are:

1. Intake Stroke
 The piston moves downward from Top Dead Center (TDC) to Bottom Dead Center
(BDC).

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Introduction to Mechanical Engineering Module 2: Engine, Future Mobility

 Intake valve opens, and a mixture of air and petrol is drawn into the cylinder.

 Exhaust valve remains closed.

2. Compression Stroke
 The piston moves upward from BDC to TDC.

 Both intake and exhaust valves are closed.

 The air-fuel mixture is compressed, increasing its pressure and temperature.

 Compressed mixture is now ready for ignition.

3. Power (Combustion) Stroke

 At TDC, the spark plug ignites the compressed air-fuel mixture.

 Rapid combustion produces high-pressure gases, forcing the piston downward.

 This downward motion generates mechanical work transmitted to the crankshaft.

 Both valves remain closed.

4. Exhaust Stroke
 The piston moves upward from BDC to TDC.

 Exhaust valve opens, and burnt gases are expelled from the cylinder.

 Intake valve remains closed, preparing for the next cycle.

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4 Stroke Diesel Engine

Working of a 4-Stroke Diesel Engine
A 4-stroke diesel engine completes one power cycle in four strokes of the piston (two crankshaft
rotations). The engine works on the Diesel cycle and uses compression ignition. The four strokes
are:

1. Intake Stroke
 The piston moves downward from Top Dead Center (TDC) to Bottom Dead Center
(BDC).

 Intake valve opens, and air only is drawn into the cylinder.

 Exhaust valve remains closed.

2. Compression Stroke
 The piston moves upward from BDC to TDC.

 Both intake and exhaust valves are closed.

 Air is compressed, raising its temperature and pressure significantly (up to ~500–
700°C).

 At the end of this stroke, the air is ready for fuel injection.

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3. Power (Combustion) Stroke

 Near TDC, diesel fuel is injected into the hot compressed air.

 The fuel ignites spontaneously, producing high-pressure gases.

 These gases push the piston downward, generating mechanical work.

 Both valves remain closed during this stroke.

4. Exhaust Stroke
 The piston moves upward from BDC to TDC.

 Exhaust valve opens, expelling the burnt gases from the cylinder.
 Intake valve remains closed, preparing for the next cycle.

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Electric Vehicles
An Electric Vehicle (EV) is a type of vehicle that runs on electric power instead of conventional
fossil fuels like petrol or diesel. EVs use an electric motor powered by energy stored in
rechargeable batteries (usually lithium-ion).

Key Components of an EV:

1. Battery Pack – Stores electrical energy.

2. Electric Motor – Converts electrical energy into mechanical energy to drive the wheels.

3. Power Electronics Controller – Manages the flow of electrical energy between the battery
and motor.

4. On-board Charger – Converts AC (from charging stations) to DC to charge the battery.

5. Transmission System – Simpler than IC engines (often single-speed).

6. Regenerative Braking System – Recovers energy during braking and sends it back to the
battery.

Types of EVs:
1. Battery Electric Vehicles (BEVs): Fully electric, no petrol/diesel engine. (e.g., Tesla
Model 3, Tata Nexon EV).
2. Plug-in Hybrid Electric Vehicles (PHEVs): Combine an electric motor with an IC engine,
can run on battery or fuel. (e.g., Toyota Prius Plug-in).

3. Hybrid Electric Vehicles (HEVs): Use both electric motor and IC engine, but battery
charging is mainly through regenerative braking, not plug-in. (e.g., Toyota Camry Hybrid).
4. Fuel Cell Electric Vehicles (FCEVs): Use hydrogen fuel cells to generate electricity. (e.g.,
Toyota Mirai).

Advantages:
 Zero tailpipe emissions (eco-friendly).

 Lower operating cost (electricity cheaper than fuel).

 High efficiency (electric motors are >90% efficient).

 Quiet operation and smooth acceleration.

 Low maintenance (fewer moving parts than IC engines).

Challenges:

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 Limited driving range (though improving with new battery tech).

 Longer charging time compared to refueling.

 Higher initial cost (battery is expensive).

 Need for charging infrastructure.

 Battery degradation over time.

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Main components of an Electric Vehicle (EV):

1. Battery Pack
 Stores the electrical energy required to run the motor.

 Usually Lithium-ion batteries (sometimes Nickel-Metal Hydride or Solid-State in newer

designs).

 Determines the driving range of the EV.

2. Electric Motor
 Converts electrical energy into mechanical energy to drive the wheels.

 Types: DC Motor, BLDC Motor, Induction Motor, Permanent Magnet Synchronous

Motor (PMSM).

 Provides instant torque and smooth acceleration.

3. Power Electronics Controller

 Acts as the brain of the EV.

 Regulates the flow of energy between the battery and motor.

 Controls torque, speed, and regenerative braking.

4. On-Board Charger (OBC)

 Converts AC (from the charging station) into DC to charge the battery.

 Manages charging rate and protects the battery.

5. Regenerative Braking System

 Recovers energy during braking.

 Converts kinetic energy of wheels into electrical energy and stores it back in the battery.

6. Transmission System
 Much simpler than IC engine vehicles.

 Often uses a single-speed gear reduction because electric motors deliver high torque
across wide speed ranges.

7. Vehicle Control Unit (VCU)

 Central computer that coordinates all vehicle operations.

 Communicates between motor, battery, brakes, sensors, and safety systems.

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8. Thermal Management System

 Maintains safe temperature of battery, motor, and power electronics.

 Uses liquid cooling or air cooling to prevent overheating.

9. Charging Port
 Connects the EV to external power sources.

 Supports different standards: Type 2, CCS, CHAdeMO, GB/T depending on the country.

10. Auxiliary Systems

 DC-DC Converter (steps down battery voltage to run small electronics).
 HVAC System (Heating, Ventilation, Air Conditioning).

 Infotainment, lighting, power steering, etc.

Hybrid vehicles
A Hybrid Vehicle (HV) is a type of automobile that combines an internal combustion engine
(ICE) with an electric motor and a battery to improve fuel efficiency, reduce emissions, and
sometimes allow short-distance pure-electric driving.

Key Components of a Hybrid Vehicle

1. Internal Combustion Engine (ICE) – Runs on petrol or diesel.

2. Electric Motor/Generator – Assists the engine and can drive the wheels on its own in
some cases.

3. Battery Pack – Stores electrical energy for the motor (usually charged through
regenerative braking and engine).
4. Power Split Device (Transmission) – Manages power distribution between engine and
motor.

5. Regenerative Braking System – Converts braking energy into electrical energy stored in
the battery.
6. Control Unit – Optimizes power usage between the ICE and electric motor for efficiency.

Types of Hybrid Vehicles

1. Micro Hybrid

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o Uses start-stop technology.

o Engine switches off at idle, restarts when needed.

o No direct drive from electric motor.

2. Mild Hybrid
o Electric motor assists the ICE (but cannot drive the car independently).

o Improves fuel efficiency.

o Example: Maruti Suzuki Smart Hybrid cars.

3. Full Hybrid (HEV)

o Can run on engine alone, motor alone, or both together.

o Example: Toyota Prius, Honda Insight.

4. Plug-in Hybrid (PHEV)

o Larger battery, can be charged from an external source (plug-in).

o Runs longer distances in pure EV mode before engine takes over.

o Example: Mitsubishi Outlander PHEV.

Working of a Hybrid Vehicle

1. At low speeds → Runs on the electric motor (silent, no emissions).

2. At moderate speeds → Uses engine + motor together for efficiency.

3. During acceleration → Electric motor assists engine for extra power.

4. During braking → Motor acts as a generator, recharging the battery (regenerative

braking).

5. At highway speeds → Mostly runs on the ICE (as it’s more efficient at steady speeds).

Advantages:
 Better fuel economy than pure ICE cars.

 Lower emissions.

 Smooth and quiet drive-in city conditions.

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Challenges:
 More expensive than normal cars.

 Battery replacement cost is high.

 Slightly complex design and maintenance.

Power Transmission System

The power transmission system in an automobile is the arrangement of mechanical components
that transmit power from the engine (or motor, in case of EVs) to the drive wheels, enabling
the vehicle to move.

Functions of Power Transmission System

1. Transmit power from engine/motor to wheels.

2. Provide torque multiplication for starting, climbing, or acceleration.

3. Allow the vehicle to run at different speeds and loads.

4. Enable reverse motion.

5. Permit the engine/motor to run at idle while the vehicle is stationary.

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Main Components (in IC Engine Vehicles)

1. Clutch (or Torque Converter in Automatics)

o Engages and disengages engine power from transmission.

2. Gearbox (Transmission)
o Provides different gear ratios for torque and speed variation.

o Types: Manual, Automatic, CVT, Dual-Clutch.

3. Propeller Shaft (in RWD/4WD vehicles)

o Transmits power from gearbox to differential.

4. Differential
o Splits power between the two drive wheels.

o Allows wheels to rotate at different speeds while turning.

5. Final Drive / Axle

o Transfers torque to the drive wheels.

Power Flow in IC Engine Vehicles

Engine → Clutch/Torque Converter → Gearbox → Propeller Shaft → Differential → Axle

→ Wheels

Power Transmission in Electric Vehicles (EVs)

 EVs are much simpler because the electric motor delivers high torque directly.

 Usually single-speed transmission (no multi-gear system needed).

 Power flow:
Battery → Inverter → Electric Motor → Reduction Gear → Differential → Wheels

Types of Transmission Systems

1. Manual Transmission
2. Automatic Transmission (AT)
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3. Continuously Variable Transmission (CVT)

4. Semi-Automatic / Dual-Clutch Transmission (DCT)

5. Electric Vehicle Single-Speed Drive

Gears:
A gear is a rotating mechanical element with teeth cut on its surface that meshes with another
toothed part (usually another gear) to transmit torque and motion between shafts.

Purpose of Gears

 To transmit power from one shaft to another.

 To change speed (increase or decrease) of rotation.

 To change torque.

 To change the direction of motion.

 To synchronize motion between mechanical parts.

Classification of Gears
Gears can be classified based on various factors such as the position of the axes, type of gearing,
and tooth design. Below is a detailed classification:

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1. According to the Position of Axes of Shafts

(a) Parallel Shaft Gears

 Shafts are parallel to each other.
Examples:

o Spur Gear – Teeth are straight and parallel to the shaft axis.
Used in simple gear trains, machine tools, etc.

o Helical Gear – Teeth are inclined to the shaft axis.

Quieter and smoother than spur gears.

(b) Intersecting Shaft Gears

 Shafts intersect at a certain angle (usually 90°).
Examples:

o Bevel Gear – Teeth are cut on a conical surface.

Used in differential drives, hand drills, etc.

(c) Non-Parallel and Non-Intersecting Shaft Gears

 Shafts neither parallel nor intersecting.
Examples:

o Worm and Worm Wheel – Used for high reduction ratios.

o Hypoid Gear – Used in automobile rear axles for smooth and quiet operation.

2. According to the Type of Gearing

 External Gearing: Teeth are on the outer surface; both gears rotate in opposite directions.

 Internal Gearing: Teeth are cut on the inner surface of a gear; both gears rotate in the same
direction.

 Rack and Pinion: Converts rotary motion to linear motion.

3. According to Tooth Form

 Straight Teeth – Simple design, used in spur and bevel gears.

 Helical Teeth – Provide smooth, quiet operation.

 Herringbone Teeth – Two helical gears of opposite hands combined to eliminate axial
thrust.

 Curved Teeth (Spiral Bevel) – Used for heavy load and high-speed operations.

4. According to the Purpose

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 Speed Gears – Used to increase/decrease speed.

 Torque Gears – Used to increase torque.

 Differential Gears – Allow wheels to rotate at different speeds (in vehicles).

Gear Trains
A gear train is a combination of two or more gears used to transmit motion and power between
shafts.

They are mainly classified into Simple Gear Train and Compound Gear Train.

1. Simple Gear Train

 Each shaft carries only one gear.

 Used when distance between driver and driven shafts is large.

 The idler gears (gears between driver & driven) do not affect speed ratio, they only change
direction of rotation.

Example:
 Gear A (driver) meshes with gear B (idler), then gear C (driven).

 Speed ratio depends only on driver and driven gears (A & C).

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Velocity Ratio, VR = N1/N2 = Z2/Z1

Where, N1 = Speed of Driver member

N2 = Speed of Driven member

Z1 = Number of Teeth on Driver member

Z2 = Number of Teeth on Driven member

2. Compound Gear Train

 At least one shaft carries more than one gear.

 These gears are rigidly fixed together and rotate at the same speed.
 Used when large speed reduction or increase is required in a compact space.

Example:
 Gear A drives gear B (on same shaft as gear C).

 Gear C drives gear D.

 Here, B and C rotate together (compound gears).

 Velocity Ratio, VR = N1/N2 = Z2/Z1 × Z4/Z3

 Where, N1 = Speed of Driver member
N2 = Speed of Driven member
Z1 = Number of Teeth on Driver member (Blue)
Z2 = Number of Teeth on Driven member (Green)
Z3 = Number of Teeth on Driver member (Red)
Z4 = Number of Teeth on Driven member (Yellow)

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Automatic Transmission
An Automatic Transmission (AT) works by transmitting engine power through a torque
converter, which replaces the clutch and allows smooth torque multiplication, into a planetary
gear set that provides different gear ratios for forward and reverse motion. The clutches and
bands, operated by a hydraulic or electronic control system, engage and disengage parts of the
gear set to change gears automatically based on speed, load, and throttle input. This enables the
vehicle to accelerate, cruise, or reverse smoothly without the driver manually shifting gears,
making driving more comfortable and efficient.

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CVT
A Continuously Variable Transmission (CVT) is a type of automatic transmission that provides
a seamless range of gear ratios instead of fixed gear steps. It uses a pair of variable-diameter
pulleys (drive and driven) connected by a strong steel belt or chain. The effective diameter of
each pulley changes continuously, adjusting the gear ratio smoothly according to driving
conditions. At low speeds, the drive pulley is small and the driven pulley is large, giving high
torque; at high speeds, the ratio reverses for efficient cruising. Controlled by hydraulics or
electronics, a CVT ensures the engine always operates in its most efficient RPM range, improving
fuel economy and providing smooth, jerk-free acceleration. It is widely used in scooters,
motorcycles, and modern cars like Toyota and Nissan models.

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